Method and apparatus for increasing compressed air efficiency in a pump

Abstract

One or more techniques and/or systems are disclosed for increasing compressed air efficiency in a pump utilizes an air efficiency device in order to optimize the amount of a compressed air in a pump. The air efficiency device may allow for controlling the operation of the air operated diaphragm pump by reducing the flow of compressed air supplied to the pump as the pump moves between first and second diaphragm positions. A sensor may be used to monitor velocity of the diaphragm assemblies. In turn, full position feedback is possible so that the pump self-adjusts to determine the optimum, or close to optimum, turndown point of the diaphragm assemblies. As such, air savings is achieved by minimizing the amount of required compressed air.

What is claimed is: 
     
       1. A pump configured to optimize an amount of supply compressed air utilized during operation, comprising:
 a first diaphragm assembly disposed in a first diaphragm chamber, said first diaphragm assembly comprising a first end-of-stroke position (EOS 1 ) and a first turndown position (X SL ), wherein the first turndown position (X SL ) comprises a different position in the first diaphragm assembly than the first end-of-stroke position (EOS 1 ); 
 a second diaphragm assembly disposed in a second diaphragm chamber, said second diaphragm assembly comprising a second end-of-stroke position (EOS 2 ) and a second turndown position (X SR ), wherein the second turndown position (X SR ) comprises a different position in the second diaphragm assembly than the second end-of-stroke position (EOS 2 ); 
 a valve configured to adjust a flow of supply compressed air to said first diaphragm chamber and to said second diaphragm chamber; 
 a first sensor configured to detect said first diaphragm assembly at said first turndown position (X SL ), wherein said detection of said first diaphragm assembly at said first turndown position (X SL ) results in said valve decreasing said supply compressed air to said first diaphragm chamber; and 
 a second sensor configured to detect said first diaphragm assembly at said first end-of-stroke position (EOS 1 ), wherein said detection of said first diaphragm assembly at said first end-of-stroke position (EOS 1 ) results in said valve increasing said supply compressed air to said second diaphragm chamber. 
 
     
     
       2. The pump of  claim 1 , further comprising:
 a third sensor configured to detect said second diaphragm assembly at said second turndown position (X SR ), wherein said detection of said second diaphragm assembly at said second turndown position (X SR ) results in said valve restricting said supply compressed air to said second diaphragm chamber; and 
 a fourth sensor configured to detect said second diaphragm assembly at said second end-of-stroke position (EOS 2 ), wherein said detection of said second diaphragm assembly at said second end-of-stroke position (EOS 2 ) results in said valve to increasing said supply compressed air to said first diaphragm chamber. 
 
     
     
       3. The pump of  claim 2 , wherein one or more of:
 said first sensor is configured to be adjustable, wherein adjusting said first sensor causes said first turndown position (X SL ) to be adjusted; and 
 said third sensor is configured to be adjustable, wherein adjusting said third sensor causes said second turndown position (X SR ) to be adjusted. 
 
     
     
       4. The pump of  claim 1 , further comprising:
 a start-up mode, comprising a preset first turndown position (X SL ); 
 a turndown position determination mode, comprising pump operation during which a desired first turndown position (X SL ) is determined; 
 an efficiency mode, comprising pump operation during which said desired first turndown position (X SL ) is utilized; and 
 a conventional mode, comprising pump operation that does not utilize said first turndown position (X SL ). 
 
     
     
       5. The pump of  claim 1 , wherein said first turndown position (X SL ) is configured to be adjustable based at least upon a velocity of said first diaphragm assembly at a first current position (X CL ). 
     
     
       6. The pump of  claim 1 , further comprises:
 a first minimum velocity (V MINL ) and a first termination velocity (V TERML ); 
 a velocity detector configured to monitor a first current velocity (V CL ) of said first diaphragm assembly while it is translated toward said second end-of-stroke position (EOS 2 ); and 
 a turndown position adjustor configured to adjust said first turndown position (X SL ) if said first current velocity (V CL ) at said second end-of-stroke position (EOS 2 ) is one of: 
 less than said first minimum velocity (V MIL ); or 
 greater than said first termination velocity (V TERRML ). 
 
     
     
       7. The pump of  claim 6 , further comprises a second minimum velocity (V MINR ) and a second termination velocity (V TERMIL ), wherein:
 said velocity detector is further configured to monitor a second current velocity (V CR ) of said second diaphragm assembly while it is translated toward said first end-of-stroke position (EOS 1 ); and 
 said turndown position adjustor is further configured to adjust said second turndown position (X SR ) if said second current velocity (V CR ) at said first end-of-stroke position (EOS 1 ) is one of:
 less than said second minimum velocity (V MINR ); or 
 greater than said second termination velocity (V TERMIL ). 
 
 
     
     
       8. The pump of  claim 5 , comprising a turndown position adjustor, wherein said turndown position adjustor is configured to determine a first redefined first turndown position (X SL1 ) that comprises a sum of said first turndown position (X SL ) and a first constant displacement value (S 1L ), wherein said first redefined first turndown position (X SL1 ) is utilized during a next pump stroke when said first diaphragm assembly is translated from said first end-of-stroke position (EOS 1 ) toward said second end-of-stroke position (EOS 2 ). 
     
     
       9. The pump of  claim 1 , one or more of the first sensor and the second sensor comprising a mechanical sensor. 
     
     
       10. The pump of  claim 1 , one or more of the first sensor and the second sensor comprising an electrical-based sensor.